Transformer assembly

ABSTRACT

A transformer assembly having a plurality of annular shaped coil chambers and adapted to receive ferromagnetic laminations and coils has a pair of insulating caps each of which includes a plurality of integrally-formed annular ribs. The annular ribs are disposed concentrically on and perpendicular to the front wall of each of the caps so as to define a plurality of concentric hollow coil chambers. Each of the chambers has a substantially rectangular cross-section. A plurality of coil sleeves is provided each having a different cross section so as to correspond with each of the ribs. Each of the coil sleeves includes end flanges and a shoulder complementary with the respective rib. The front wall of at least one cap contains apertures as directed to the connecting flange side of the respective coil chamber. The connecting flange side bears overlapping teeth. Electrical connection means are disposed along the outside portion of each of the caps providing a means for electrical connection to the coil windings. The ribs are placed so as to seat along the shoulders of the sleeves thereby defining a plurality of closed coil chambers and included in a coil space devoid of any ribs.

United States Patent [1 1 Weiner [4 1 Dec. 25, 1973 TRANSFORMER ASSEMBLY[76] Inventor: Norbert Weiner, Pernze 5275,

Bergneustadt, Germany [22] Filed: June 18, 1973 [21] Appl. No.: 370,871

[30] Foreign Application Priority Data Primary Examiner-Thomas J. KozmaI Attorney-Allison C. Collard [57] ABSTRACT A transformer assemblyhaving a plurality of annular shaped coil chambers and adapted toreceive ferromagnetic laminations and coils has a pair of insulatingcaps each of which includes a plurality of integrallyformed annularribs. The annular ribs are disposed concentrically on and perpendicularto the front wall of each of the caps so as to define a plurality ofconcentric hollow coil chambers. Each of the chambers has asubstantially rectangular cross-section. A plurality of coil sleeves isprovided each having a different cross section so as to correspond witheach of the ribs. Each of the coil sleeves includes end flanges and ashoulder complementary with the respective rib. The front wall of atleast one cap contains apertures as directed to the connecting flangeside of the respective coil chamber. The connecting flange side bearsoverlapping teeth. Electrical connection means are disposed along theoutside portion of each of the caps providing a means for electricalconnection to the coil windings. The ribs are placed so as to seat alongthe shoulders of the sleeves thereby defining a plurality of closed coilchambers and included in a coil space devoid of any ribs.

10 Claims, 6 Drawing Figures TRANSFORMER ASSEMBLY This invention relatesto a coil or transformer body for a cylinder type assembly. The coilbody has a plurality of annular shaped coil chambers which aresuperimposed vertically with respect to the annular cylindrical axis.The coil chambers essentially comprise bushing or sleeve portions havingend flanges, two insulating caps, having a front wall and a slip-onbushing. The slip-on bushing of each cap slips over a'front flange ofthe coil or winding sleeves while the engaging front edges slip overeach other in a folded manner.

It has been found that coils that are made in a cylinder type assemblyhave a lesser leakage than coils made in a disc type assembly.Cylindrically formed coils have been found to be better suited for thehigher audio frequencies.

However, such coil or transformer bodies, in particular, bodies havingrather small dimensions will not always meet the standards set forth bythe Society of German Electrical Engineers and in particular standard [IVDE 0551. A transformer body of the above type is disclosed in Germanlaid open patent 1,932,174, dated .lan. 14, 1971. However, the bodydisclosed has relative broad flanges that are required at the coilchambers, whereby coil chamber space is lost. This leads to undesirablelosses and to increased requirements for space.

It is therefore, an object of the present invention to provide atransformer body which meets the aforementioned standards and which moreefficiently utilize coil chamber space.

Accordingly the objects of the present invention are obtained byproviding an annular rib on the inner wall of the front wall of eachinsulating cap for each coil chamber. The annular rib has about half ofthe wall thickness of the sleeve portion. Each coil chamber is providedwith a front face shoulder at the inner face of the sleeve portion andhas half of the wall thickness of the sleeve portion andextends indirection of the angular axis equal to the length of the annular rib.The annular rib fills out the cross section of said front face shoulderof the sleeve portion of the respective coil chamber so that the innersurface of said rib is flushed with the inner surface of the sleeveportion.

This arrangement provides that the insulation path is essentially thesame length as the aforementioned annular rib. This annular rib can beso arranged that the required insulation path is provided, inparticular, in smaller coil bodies.

The insulation path should be so long as is requested by competentauthorities. The transformer body permits voltages in excess of 18,000volts. The flanges of the coil chambers may be as thin as desired. It isonly necessary they act effectively under the desired voltage level.Therefore, each coil chamber can be wound about the total axial lengththereby utilizing a large portion of the transformers body in thewinding. Each transformer body may be dimensioned for the desiredoutput. It is very important to keep leakage as low as possible. It isalso important that the inventive transformer body meet all therequirements of the aforementioned standards. This is particularlyimportant when small transformer bodies are involved, so that theinventive body may be used, for example, as audio frequencytransformers, and output transformers of auxilliary loud speakers inradios and televisions.

In a preferred embodiment of the invention the front portion of thebushing of one of the insulating caps is displaced by the amount of thewall thickness and is increased by the length of the insulating path. Inthis way, the insulating caps may be provided with relatively thinwalls.

In accordance with a further embodiment of the invention an opening isprovided in the front wall of each insulating cap on the side of theconnecting flange of each coil chamber. The coil wires can be easilymounted and provide the means for connecting wires to adjoining oradjacent contact pins yet still maintain the desired insulation path.

In a further embodiment in accordance with the invention, an insulatingplate is provided beneath each opening at the inner side of thecorresponding insulating cap. The insulating plate extends outwardly andvertically with respect to the front wall face. This insulating plateprovides a sufficient insulation with respect to the core plates.

In still a further embodiment of the invention, an opening is providedin one insulating cap for the inner coil chamber and an opening in theother insulating cap for the outer coil chamber. This arrangement isparticularly advantageous for a horizontal connection of thetransformer.

In still a further embodiment of the invention, an opening for the outercoil chamber and, an opening for the inner coil chamber are provided atthe front wall of one of the insulating caps. This arrangement of theopenings in one front face permits extension of the coil wires throughonly one front wall and thereby increase the protective insulation ofthe coil body. This arrangement permits a vertical connection of thetransformer body.

Other objects and features of the present invention will become apparentfrom the following detailed description when taken in connection withthe appended drawings to which reference should be made. It is to beunderstood, however, that the drawings are designed for the purpose ofillustration only and are not intended as a definition of the limits andscope of the invention.

In the drawings, wherein similar reference numerals denote similarelements throughout the several views:

FIG. 1 is a partial cross section view ofa coil body for horizontalconnection showing the core plates inserted;

FIG. 2 is a side view according to FIG. 1 but without core plates;

FIG. 3 is a plan view partly in section according to FIG. 1;

FIG. 4 is a view ofa coil body for vertical connection partially cut andshowing the core plates inserted;

FIG. 5 is a view according to FIG. 4 taken in the direction of arrow V;and

FIG. 6 is a plan view according to FIG. 4 also partially cut.

Referring now to the figures, there is shown a transformer body havingtwo coil chambers in a substantially rectangular cross section. Oneinner coil chamber 1 is provided with a bushing or sleeve portion 2 aswell as two end flanges 3 and 4. Openings 5 for the coil wires orwindings are provided in connecting flange side 4' of coil chamber 1.The required wall thickness of coil chamber 1 is designed in accordancewith the mechanical as well a the dielectric strength of the employedmaterial. A shoulder 6 is provided on the front face of the inner faceof the sleeve portion. The width of the shoulder corresponds to abouthalf ofthe wall thickness of the coil chamber and the lengths indirection of the chamber axis correspond to the desired path ofinsulation.

A further coil chamber 7 encompasses coil chamber 1 in radial direction,whereby the coil chamber 7 is constructed in the same manner as the coilchamber 1.

Thus, the same numeral references may be used for both chambers.However, the connecting flange side 4' of coil chamber 7 which containsthe openings for the coil wires are opposite to the flange 4 of coilchamber 1. The coil windings are not shown in the drawing.

Two insulating caps 8 and 9 are slipped over the coil chambers 1 and 7.Insulating cap 8 is provided with a front wall 10 as well asintegrally-formed bushing 11 which extends over a portion of the axiallength of the coil chambers. An opening 12 is provided in front wall 10of insulating cap 8 which is directed to the connecting face of flangeside 4 of the inner coil chamber 1. Two annular ribs 13 are providedat'the front wall 10 for each of'the coil chambers l and 7,respectively.

These annular ribs 13 run in the axial direction of the coil chamber andencompassa cross section which is equal to the inner cross section ofthe corresponding coil chamber,.The wall thickness of each annular rib13 is equal to half of the wall thickness of coil chambers 1 and 7,respectively. The length of each annular rib 13 in the axial directionof the coil chambers is equal to the lengths of shoulders 6. Therefore,the annular ribs 13 completely fill out the shoulders 6 (seen in FIGS. 1and 3). The annular ribs 13 are flush with the inner face of bushingportions 2, so that the inner space of the sleeve portions is notrestricted and may be completely used for winding the inner coilchamber, or for the core plates or laminations 14. Insulating cap 8carries an in sulating plate 15 which is mounted below opening 12. Thisinsulating plate 15 may be provided with an angular shank 16, seen inFIG. 1. Insulating plate l5receives the connecting elements 17 thatmight comprise soldered terminals, clamp terminals or connecting pins.

Insulating cap 9'is essentially the same as insulating cap 8. However,at the front face of slip-on bushing 11 is mounted an annular front ring18 that is displaced to the outside byv the amount of the wall thicknessof the insulating cap. The axial length thereof is increased inaccordance withthe desired insulating path. Hence, insulating cap 9 maybe telescopically slipped over insulating cap 8. Insulating cap 9 isprovided with an opening 12 in front wall 10, whereby the opening isdirected to the connecting flange 4 of outer coil chamber 7. Opening 12'is opposite opening 12 when viewed in axial direction of the coilchambers.

As can be seen from FIGS. 1 and 3, the total coil space of each coilchamber 1 and 7 can be totally used. At no place has there been therequirement that the coil chamber be reduced in size. Annular ribs 13and front face ring 18 provide a sufficient insulating path for thecoils as well as for the core plates. This coil body is designed for ahorizontal connection as in a switch board.

Referring to FIGS. 4 and 6 a coil body is shown adapted for use in thevertical position on a switch board. Coil chambers 1 and 7 areessentially the same in their construction as the coil chambersdescribed above. The same is true for the insulating caps 8 and 9.However, in opposite portion 10' of the front wall 10, insulating cap 9is provided with an opening 12 for the inner coil chamber 1 and anopening 12' forthe outer coil chamber 7. The connecting flange sides 4'which are directed to openings 12 and 12 are provided with correspondingopenings '5 for the coil wires. Each connecting flange side 4"bearsseveral groups 20 of ridgelike overlapping teeth 21 between which theends of coil wire can be clamped. Insulating plates 15 are mounted inthe inner portion of the insulating cap 9 beneath openings 12 and 12 sothat the insulating plates extend outwardly from the front wall. Anouter rib 18 which is mounted on portions 10 is provided with connectingpins 17. Lateral ribs or flanges 19 support outer rib 18, so that theconnecting pins 17 are securely held. The connecting pins are providedwith receiving elements' for the metallic plug parts. Consequently, theinventive coil body permits protective insulation of the coil body whenvertically mounted. The teeth 21 are very advantageous forthe winding ofthe coil since the ends of the coil wire can be clamped withoutdifficulties. After the insulating caps 8 and 9 are slipped over thecoil chambers the ends of the coil wires are detached from the teeth 21and connected with the respective connecting pins 17.

While only several embodiments of the present invention have been shownand described, it will be obvious to those persons of ordinary skill inthe art that many changesand modifications may be made thereunto withoutdeparting from the spirit and scope of the invention.

What is claimed is: 1. A coil body assembly having a plurality ofannular shaped coilchambers and adapted to receiveferromagnetic-laminations and coils comprising:

' a pair of insulating caps each of which includes a plurality ofintegrally formed annular ribs, said ribs disposed concentrically on andperpendicular to the front wall of each of said caps so as to define aplurality of concentric hollow'coil chambers each of the chambers havinga substantially rectangular cross section; a plurality of coil sleeveseach having a different cross section so as to be corresponding witheach of said ribs, each of. said sleeves including end flanges andshoulders complementary with said ribs; and I i electrical connectionmeans disposed along the outside portion of at least one of said capsproviding a means for electrical connection to the coil windings, saidcap ribs being placed so as to seat along the shoulders and therebydefine a plurality of closed coil chambers and an included inner coilspace devoid of said ribs.

2. The coil body as in claim 1 wherein the thickness of said ribs andthe sleeve shoulders are approximately half the thickness of said coilsleeve so that each of said ribs mate with said complementary coilsleeve without discontinuity of cross section.

3. The coil body asin claim 2 further including an insulating platedisposed substantially perpendicular to and placed on each of saidinsulating caps, and plates oppositely directed from said plurality ofsaid ribs so as to receive and confine the ferromagnetic laminations.

4. The coil body as in claim 3 wherein said electrical connection meansincludes a plurality of conductive equal number of said pins disposed oneach one of said insulating cap plates.

5. The coil body as in claim 2 wherein one of the insulating capsfurther includes a pair of parallel spacedapart insulating plates forreceiving and confining the ferromagnetic laminations therebetween, saidplates disposed perpendicular to said insulating cap and oppositelydirected from said ribs.

6. The coil body as in claim 5 wherein said electrical connection meanscomprises a plurality of outer flanges disposed on the outer rim of onecap and in parallel alignment to of said insulating plates, and whereinsaid electrical connection means includes electrical connection pinsdisposed in and supported by said flanges, said pins being disposedsubstantially parallel to said insulating plates.

7. The coil body as in claim 6 wherein said insulating cap containingsaid insulating plates further includes a plurality of aperturesprovided therethrough allowing access to each of the coil chambers.

8. The coil body as in claim 4 wherein said insulating cap includes aplurality of apertures providing access to each of the coil chambers.

9. The coil body as in claim 2 wherein one of said insulating capsincludes an integrally formed insulating end ring disposed on bushingportion, said insulating end ring flaring slightly outwardly so as topartially cover said complimentary bushing portion of said otherinsulating cap.

10. The coil body as in claim 7 wherein said coil sleeve bears on oneside of one end flange teeth disposed perpendicular to said flange andextending through the apertures.

1. A coil body assembly having a plurality of annular shaped coilchambers and adapted to receive ferromagnetic laminations and coilscomprising: a pair of insulating caps each of which includes a pluralityof integrally formed annular ribs, said ribs disposed concentrically onand perpendicular to the front wall of each of said caps so as to definea plurality of concentric hollow coil chambers each of the chambershaving a substantially rectangular cross section; a plurality of coilsleeves each having a different cross section so as to be correspondingwith each of said ribs, each of said sleeves including end flanges andshoulders complementary with said ribs; and electrical connection meansdisposed along the outside portion of at least one of said capsproviding a means for electrical connection to the coil windings, saidcap ribs being placed so as to seat along the shoulders and therebydefine a plurality of closed coil chambers and an included inner coilspace devoid of said ribs.
 2. The coil body as in claim 1 wherein thethickness of said ribs and the sleeve shoulders are approximately halfthe thickness of said coil sleeve so that each of said ribs mate withsaid complementary coil sleeve without discontinuity of cross section.3. The coil body as in claim 2 further including an insulating platedisposed substantially perpendicular to and placed on each of saidinsulating caps, and plates oppositely directed from said plurality ofsaid ribs so as to receive and confine the ferromagnetic laminations. 4.The coil body as in claim 3 wherein said electrical connection meansincludes a plurality of conductive connecting pins disposed on each ofsaid caps and perpendicular to said plates, and having a substantiallyequal number of said pins disposed on each one of said insulating capplates.
 5. The coil body as in claim 2 wherein one of the insulatingcaps further includes a pair of parallel spaced-apart insulating platesfor receiving and confining the ferromagnetic laminations therebetween,said plates disposed perpendicular to said insulating cap and oppositelydirected from said ribs.
 6. The coil body as in claim 5 wherein saidelectrical connection means comprises a plurality of outer flangesdisposed on the outer rim of one cap and in parallel alignment to ofsaid insUlating plates, and wherein said electrical connection meansincludes electrical connection pins disposed in and supported by saidflanges, said pins being disposed substantially parallel to saidinsulating plates.
 7. The coil body as in claim 6 wherein saidinsulating cap containing said insulating plates further includes aplurality of apertures provided therethrough allowing access to each ofthe coil chambers.
 8. The coil body as in claim 4 wherein saidinsulating cap includes a plurality of apertures providing access toeach of the coil chambers.
 9. The coil body as in claim 2 wherein one ofsaid insulating caps includes an integrally formed insulating end ringdisposed on bushing portion, said insulating end ring flaring slightlyoutwardly so as to partially cover said complimentary bushing portion ofsaid other insulating cap.
 10. The coil body as in claim 7 wherein saidcoil sleeve bears on one side of one end flange teeth disposedperpendicular to said flange and extending through the apertures.